Protective ball cap

ABSTRACT

A protective insert for a ball cap and a cap incorporating the same. The insert includes a rigid shell and a complementary impact-absorbent liner that covers and protects only the forehead and portions of the sides of the user&#39;s head. Bottom edges of the shell, liner and cap are generally aligned along the same horizontal plane. Alternatively, the shell and liner terminate a distance inwardly from the bottom edge of the cap. An adjustable band is secured to the ends of the shell and the band and shell encircle the circumference of the user&#39;s head. One or more engagement members may secure the insert to the cap. The material of the liner is thicker in a front central region and thinner toward the side regions of the insert. The liner material extends beyond the top edge of the shell so that the shell does not directly contact the user&#39;s head.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation-in-Part of U.S. patent application Ser. No. 29/513,002 filed Dec. 24, 2014, which is a Continuation-in-Part of U.S. patent application Ser. No. 13/942,179, filed Jul. 15, 2013, the entire specifications of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Technical Field

This invention is directed to hats. More specifically, this direction is directed to hats or caps. Most particularly, this direction is directed to a cap which includes a protective insert. Specifically, the cap has the appearance of a traditional ball cap and the insert includes a rigid shell and an impact absorbent liner which only cover and protect the user's forehead and the sides of their head, and where each of the shell and liner have bottom edges that are generally aligned with a bottom edge of the cap and are therefore substantially invisible to onlookers.

2. Background Information

One of the issues that tee-ball, baseball and softball users may experience is that a struck ball, such as one hit in a line drive, or a bat that is accidentally released may strike a user in the head, causing an impact injury such as a concussion, a fracture or catastrophic impacts that may cause intracranial bleeding leading to death. This is particularly problematic when it comes to ball games played by younger, less experienced and less skilled users who may not be able to direct a struck ball in a particular direction with any certainty. This type of injury may also occur if a ball or bat strikes a spectator by accident.

While many users, such as batters wear protective helmets, a large percentage of users do not or will not wear such protective gear. Additionally, it is highly unlikely that any spectator will be wearing some type of protective helmet when they show up to watch a game. Traditionally both users and spectators prefer to wear a traditional baseball cap.

There have been a number of attempts made in the past to provide protection on the outside of a ball cap, but the fact is if the protective components cover the “team” logo or if the hat looks bulky and somehow not traditional, children, in particular, will not wear such a cap.

There have also been numerous attempts at providing protective components in interiors of hats but many of the resultant products have been bulky and unsightly and therefore less desirable for people to wear.

Examples of previously known devices include that disclosed in U.S. Pat. No. 3,268,911 (Cox). Cox discloses a conventional hat having a dome-shaped protective shell made of hard plastic received therein. The shell is configured complementary to the inner surface of the hat and fits snugly within the space defined by the hat's inner surface. A generally X-shaped harness assembly made of a flexible plastic is disposed within a space defined by the shell. The harness is secured to a bottom region of the shell by cooperating buttons and holes disposed on the shell and harness. When the harness is engaged in the shell, a crown region of the harness rests on the top of the user's head and the crown-region is disposed a distance downwardly away from the protective shell. An annular sweatband is secured to the ends of the harness and is disposed aligned with an annular bottom region of the shell and inside the bottom edge of the hat. Resilient pads are glued at intervals to the inner surface of the shell. In particular, the pads are provided at the crown region of the shell and at spaced temple positions around the circumference of the shell. The spacing between the pads allows for ventilation of the hat. The harness engages the user's head and the protective pads and the shell are thereby disposed a short distance from the user's head. The user's head is not in contact with the pads.

Heine et al (U.S. Pat. No. 4,675,919) discloses a headband for mounting of optical instruments. The headband includes a first region which passes around the circumference of the head and a second region which extends from the first region and passes over the user's head. Cushioning pads are detachably engaged around portions of the first and second regions and contact the user's head. There is no disclosure in the patent that the headband provides any type of protection for the head, just that the headband is useful for mounting instruments thereon.

Graham (U.S. Pat. No. 4,982,451) discloses a resilient adjustable liner for a hat, particularly a soft, yarn hat. The liner is fabricated from a resilient and flexible plastic that is U-shaped when viewed from the top. The liner includes a central region that is configured to be disposed adjacent the back of a user's head and two side regions that are configured to extend downwardly over the user's cheeks. A slot in the band is positionable over the user's forehead. The liner is of uniform thickness along its entire length. Plastic fasteners engage the liner to the hat. Apertures are provided in the liner in a location which will fall adjacent the user's ears. The hat is pulled over the liner and covers the entire liner.

Benston et al (U.S. Pat. No. 5,025,504) discloses a disposable liner for a hat or cap which is an elongate, trapezoidally-shaped member that is adhered to a portion of the inner surface of the hat or cap. The liner includes a central region for positioning adjacent the user's forehead and two tapering side regions extending outwardly from the central region. The side regions are configured so as to extend across the region of the user's head across the upper regions of their temples. The liner is designed as a sweatband and includes a liquid absorbing material disposed between an interior and exterior wall. The liquid absorbing material is disposed in discrete pockets which are separated from each other by regions which are free of liquid absorbing material.

Leach (U.S. Pat. No. 5,226,180) discloses a golfing helmet that includes an outer hat or cap that is conventional. An impact absorbing Styrofoam liner is placed in the interior of the cap. The hemispherical liner includes elongate openings for ventilation. The liner is glued into the cap. Similarly, Anderson (U.S. Pat. No. 5,289,591) discloses a plastic insert for a golf cap. The insert is generally hemispherical except for a semi-circular cut-out in the back of the insert which allows for adjustment of the cap. The insert is provided with apertures for ventilation.

U.S. Pat. No. 5,437,064 (Hamaguchi) discloses a protective cap that includes a first padding assembly comprising a circular band that is configured to encircle a user's head and be seated inside the bottom edge of a hat. The first padding assembly also includes two semi-circular bands which are connected to the circular band and are configured to pass from front-to-back and from side-to-side across the crown of the user's head. The first padding assembly is detachably secured to the inside of the hat by way of hook and loop fasteners. The protective cap further includes a second padding assembly which is received within a space defined by the first padding assembly. The second padding assembly includes an outer fabric layer and an inner resilient foam layer. The second padding assembly is configured to contact the user's head.

Moore, III et al (U.S. Pat. No. 6,154,889) discloses a protective helmet made from a resilient shell that has a plurality of radial slits therein which enable the shell's width to be adjusted. The shell is fabricated from a hard material and a liner fabricated from an energy absorbing material is disposed inside the shell. The shell is a hemispherical dome and includes regions which extend downwardly to cover a user's temples.

Blair (U.S. Pat. No. 7,096,512) discloses a protective sports hat insert which includes a solid outer shell, an inner high-density foam liner, and may include a washable cloth layer. The outer shell is domed and hemispherical in shape and the inner liner is complementary in shape to the outer shell. The inner liner may be fabricated in a variety of configurations that may be “folded into” the space defined by the outer shell. Preferably, inner liner is spaced from outer shell to provide some additional shock absorption when the hat receives an impact blow. The inner liner tapers at its bottom edge.

Motroni (US 2012/0131731) discloses an insert for a ball cap. The insert is configured to extend along the front wall of the cap and thereby protect the forehead of the user. The insert is made from plastic and may be placed adjacent the front wall or be glued or otherwise secured in place.

SUMMARY

While all of the above protective devices work adequately for the purposes for which they were intended, there remains a need in the art for an improved protective cap which has the outward appearance of a traditional cap but which aids in protecting the most vulnerable areas of the user's head.

A protective insert for a ball cap and a cap incorporating the same. The insert includes a rigid shell and a complementary impact-absorbent liner that covers and protects only the forehead and portions of the sides of the user's head. Bottom edges of the shell, liner and cap are generally aligned along the same horizontal plane. Alternatively, the shell and liner terminate a distance inwardly from the bottom edge of the cap. An adjustable band is secured to the ends of the shell and the band and shell encircle the circumference of the user's head. One or more engagement members may secure the insert to the cap. The material of the liner is thicker in a front central region and thinner toward the side regions of the insert. The liner material extends beyond the top edge of the shell so that the shell does not directly contact the user's head.

In one aspect, the invention may provide a protective insert for a cap to be worn on a user's head, said insert comprising an outer shell adapted to be received within a space defined by an inner surface of an outer wall of the cap; said shell being adapted to cover only the user's forehead and sides of their head; and an inner liner complementary in shape to the outer shell; wherein the liner is positioned adjacent an inner surface of the shell and is adapted to be disposed adjacent the user's head.

In another aspect, the invention may provide a cap assembly for protecting a user's head; said assembly comprising a cap including a substantially hemispherical outer wall having an inner surface and a bottom edge; a space defined by the inner surface of the outer wall; and a protective insert receivable within the space; wherein said insert comprises an outer shell adapted to cover only the user's forehead and sides of their head; an inner liner complementary in shape to an interior surface of the outer shell; wherein the liner is adapted to be disposed adjacent the user's forehead and the sides of the user's head; wherein each of the shell and liner has a bottom edge and wherein the bottom edges of the liner and the shell do not extend beyond the bottom edge of the cap.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

A sample embodiment of the invention, illustrative of the best mode in which Applicant contemplates applying the principles, is set forth in the following description, is shown in the drawings and is particularly and distinctly pointed out and set forth in the appended claims.

FIG. 1 shows a perspective view of a ball cap in accordance with an aspect of the present invention with the cap being shown worn on a user's head and showing a portion of a first embodiment of a protective insert extending outwardly from the cap and positioned adjacent the user's temple;

FIG. 2 is a perspective view of the first embodiment of the protective insert for the ball cap shown worn on the user's head but with the cap removed from the user's head for clarity;

FIG. 3 is a perspective view of the insert removed from the user's head;

FIG. 4 is an exploded perspective view of the insert of FIG. 3;

FIG. 5 is a top view of the insert;

FIG. 6 is a left side view of the insert;

FIG. 7 is a front plan view of the insert;

FIG. 8 is a bottom perspective view of the insert;

FIG. 9 is an enlarged perspective view of the highlighted region of FIG. 3;

FIG. 10 is a cross-sectional side view of the ball cap with insert engaged therewith shown worn on a user's head;

FIG. 11 is a cross-sectional front view of the ball cap and insert worn on a user's head with the cross-section being taken along line 11-11 of FIG. 6;

FIG. 12 shows a perspective view of a ball cap in accordance with an aspect of the present invention with the cap being shown worn on a user's head; where the ball cap includes a second embodiment of a protective insert but that insert is substantially not visible to an observer;

FIG. 13 is a perspective view of the second embodiment of the protective insert for the ball cap shown worn on the user's head but with the cap removed from the user's head for clarity;

FIG. 14 is a perspective view of the insert removed from the user's head;

FIG. 15 is an exploded view of the second embodiment of the insert;

FIG. 16 is a second perspective view thereof;

FIG. 17 is a right side view of the protective liner for a ball cap; the left side view not being illustrated herein but being a mirror image thereof;

FIG. 18 is a bottom view of the protective liner for a ball cap;

FIG. 19 is a top view thereof;

FIG. 20 is a front view thereof; and

FIG. 21 is a rear view thereof.

Similar numbers refer to similar parts throughout the drawings.

DETAILED DESCRIPTION

Referring to FIGS. 1-11, there is shown a ball cap assembly 10 which includes a cap 11 and a first embodiment of a protective insert 12. FIGS. 12-20 show a ball cap assembly 110 which includes a cap 11 and a second embodiment of a protective insert 112. Cap assemblies 10 and 110 are configured to have the appearance of a traditional baseball cap that is worn by players and spectators of the game. Cap assemblies 10, 110 may, in fact, include a traditional baseball cap 11 that is worn on a user's head 14. It will be understood that while a traditional baseball cap 11 is illustrated in the attached figures, other types of hats and caps worn by golfers and other athletes can be provided with a protective insert 12 or 112 in accordance with aspects of the present invention. In those instances, the insert will be configured to be complementary to the specific shape and features of the hat or cap in question.

Cap 11 comprises a substantially dome-shaped wall 16 which has an exterior surface 16 a and an inner surface 16 b (FIG. 10). Wall 16 has a bottom edge 16 c which substantially circumscribes the user's head 14 when cap 11 is worn thereon. Wall 16 includes a frontal region and a peak 18 extends outwardly and forwardly away from the bottom edge 16 c. Cap 11 has an interior diameter “D” (FIG. 10) which closely approximates the diameter of the user's head 14. Cap 11 defines an interior chamber 22 (FIG. 10) into which both insert 12 and the user's head 14 are received.

FIG. 2 illustrates insert 12 alone engaged about the user's head 14. In this figure, cap 11 has been removed for clarity. FIG. 3 illustrates insert 12 standing on its own and not engaged about a user's head. It will be noted that the insert 12 is not the traditional domed hemispherical shape that covers the entire head of the user. Instead, insert 12 is configured to protect the user's forehead, temples and areas immediately above the ears. The crown and back of the user's head do not have any portion of the insert 12 covering them, except for the regions covered by securing straps, as will be later described herein. This configuration of insert 12 fits into a traditional cap 11 and protects the most vulnerable portions of the head but has the additional benefit of allowing air to circulate freely around the crown and back of the head.

FIG. 4 shows an exploded view of insert 12 and in this view it can be seen that insert 12 comprises a first component and a second component. The first component is an outer shell 24 and the second component is a pad 26. Pad 26 is configured to be complementary to at least a front portion of outer shell 24. Pad 26 may be adhesively engaged with shell 24 or shell 24 may be placed in a mold and the foam pad 26 is injection-molded around shell 24.

Referring to FIGS. 4 and 5, outer shell 24 has an exterior surface 24 a, an inner surface 24 b, a top edge 24 c and a bottom edge 24 d. Pad 26 has an exterior surface 26 a, an inner surface 26 b, a top edge 26 c, and a bottom edge 26 d. As is evident from the figures, pad 26 is configured to be engaged with outer shell 24 such that inner surface 24 b of shell 24 is disposed adjacent exterior surface 26 a of pad 26. Outer shell 24 may be fabricated from a relatively thick, strong and rigid material such as polycarbonate plastic. Pad 26 may be fabricated from a high density foam that will tend to readily absorb impact forces. Pad 26 may be provided to decelerate impact from a ball hit and is fabricated from a visco-elastic material or foam having a heavy density of around 0.38 g/cm3.

Shell 24 may be approximately 0.1″ thick and pad 26 varies in thickness from about 0.1″ thick to about 0.32″ thick, with the thickness being measured between the respective interior and exterior surfaces of shell 24 and pad 26. Pad 26 may be a molded foam pad of complex geometry and has verifying thickness in that frontal region 50 is thicker than terminal regions 54. Pad 26 tapers between frontal region 50 and terminal regions 54 so that there is a smooth transition to band 34. The tapering pad thickness also helps ensure that the overall circumference of cap 11 is kept as small as possible.

Outer shell 24 includes a frontal region 28 sized and positioned to cover and protect the user's forehead 14 a. Outer shell 24 further includes at least one but preferably a pair of temporal regions 30 (FIG. 7). Temporal region 30 is a projection which extends downwardly beyond or below bottom edge 24 d of outer shell and is positioned and shaped to at least partially cover and protect one of the user's temples. Outer shell 24 may include two opposed temporal regions 30 which are opposed projections that extend outwardly and downwardly below bottom edge 24 d of outer shell and each of these projections at least partially covers and projects one of the user's temples.

Each temporal region 30 may be generally V-shaped and when pad 26 is engaged with shell 24, at least a portion of each V-shaped temporal region 30 will extend for a distance downwardly below bottom edge 16 c of cap 11. (It will be understood that the projections that comprise temporal region 30 may be shaped differently. For instance, they may be generally semi-circular in shape.) A terminal region 32 extends rearwardly from each temporal region 30 and is configured to cover and protect a portion of the sides of the user's head immediately above the ear 14 b (FIG. 11).

A band 34 extends between the opposed terminal regions 32 of shell 24 and is threaded through apertures 36 defined in each terminal region 32. Band 34 is adjustable to fit the user's head and thereby retain shell 24 and pad 26 adjacent thereto. Band 34 is semi-circular in shape and is configured to form a horizontally oriented semi-circular arch. Band 34 in conjunction with outer shell 24 fits circumferentially around the user's head 14 in a horizontal orientation.

In accordance with an aspect of cap assembly 10, at least one engagement member is provided on one or both of outer shell 24 and wall 16 to secure the insert 12 to cap 11. The engagement member includes but is not limited to one or more pin members 38, a detent 60 or hook and loop fasteners (not shown). The engagement member(s) extend outwardly and forwardly from frontal region 28 of shell 24 and toward inner surface 16 b of outer wall 16 of cap 11. Alternatively, the engagement member(s) may be provided on cap 11 and extend inwardly toward shell 24.

A first engagement member is provided in the form of one or more pin members 38 provided on exterior surface 24 a of shell and which extend toward and engage inner surface 16 b of wall 16 adjacent frontal region 28. Pin members 38 interlockingly engage cap 11 and shell 24 together. Pin members 38 may be disposed in one or more rows or columns in an area of shell 24 that will directly overlay the user's forehead. Pin members 38 may be spaced at intervals a distance apart from each other and they may be of uniform diameter along their lengths. Pin members 38 frictionally engage the inner surface of outer wall 16 and thus aid in preventing cap 11 from lifting upwardly off insert 12 when the wind blows.

In accordance with yet another aspect of cap assembly 10, a first strap 40 and a second strap 42 are provided on insert 12. First strap 40 extends between opposed flanges 44 provided on terminal regions 32 of shell 24. First strap 40 is threaded through an aperture 46 (FIG. 4) in each flange. Although not illustrated herein, it will be understood that hook and loop fastener strips are provided on an exterior surface of first strap 40 proximate each free end 40 a, 40 b (FIG. 7) thereof and on an inner surface of each free end 40 a, 40 b. The hook and loop fastener strips enable the overall length of first strap 40 between flanges 44 to be adjusted. First strap 40 is semi-circular in shape and is configured to pass from side-to-side of outer shell 24 and pass over the crown of the user's head. First strap 40 thus forms a vertically oriented semi-circular arch relative to outer shell 24. First strap 40 does not engage band 34 which passes around the back of the user's head.

As best seen in FIG. 9, second strap 42 is threaded through an aperture 48 defined in frontal region 28 and extends rearwardly therefrom. Second strap 42 may be fixedly secured to first strap 40 approximately midway between flanges 44. Second strap 42 may be stitched to first strap 40 or be otherwise fixedly secured thereto. Second strap 42 may also be fixedly secured to frontal region 28 by threaded free end 42 a thereof through aperture 48 and stitching free end 42 a to a portion of second strap 42. Thus, second strap 42 may be of a fixed length as measured between frontal region 28 and first strap 40. Although not illustrated herein, it will be understood that hook and loop fastener strips may, alternatively, be provided between free end 42 a of second strap 42 and the inner surface of second strap 42 so that the overall length of second strap 42 between frontal region 28 and first strap 40 is able to be adjusted so as to more closely fit the user's head 14. Second strap is configured to be curved and pass from the front of the user's head to the crown of their head. Second strap 42 does not extend to the back of the user's head.

Thus, first strap 40 extends from proximate the user's left ear 14 b to proximate the user's right ear 14 b. The second strap 42 extends from proximate the top of the user's forehead to proximate the crown of the user's head. At least two of these three bands/straps 34, 40, and 42 may be adjustable so that the user can change the overall dimensions of insert 12 to most closely and snugly fit their head. Each of band/straps 34, 40 and 42 may be fabricated from a flexible fabric material, such as a cotton fabric, which makes them relatively easy to adjust. This helps ensure that the protective outer shell 24 and pad 26 are located in the optimum positions on the user's head to protect them from impact. Apart from apertures 36, 46, 48 outer shell 24 is substantially continuous and uninterrupted along its length and width.

Protective pad 26 is complementary in shape to the rigid outer shell 24. Only the three bands/straps 34, 40 and 42 on the outer shell 24 are free of any of the padding material. Thus as shown in FIG. 4, pad 26 includes a frontal region 50, opposed temporal regions 52, and opposed terminal regions 54. Temporal regions 52 are also generally V-shaped members that extend below bottom edge 16 c of wall 16. As best seen in FIG. 1, temporal regions 52 may be each slightly bigger than temporal regions 30 of shell 24. Pad 26 is slightly larger in height than shell 24 so that a lip of foam padding extends above and below the upper and lower edges of shell 24. The foam lip extends around substantially the entire outer edge of shell 24 so there are no unprotected edges of the stiff outer shell 24 that could injure or cut the user if impacted by a bat or ball. Pad 26 is comprised of an impact-absorbing material and this material is substantially continuous along the entire inner surface 24 b of outer shell 24. Thus, there are substantially no regions on inner surface 24 b that are free of the impact-absorbing material.

As best seen in FIGS. 6 and 7, substantially the entire bottom edge 24 d of shell 24 lies generally along a plane “P”. Similarly, substantially the entire bottom edge 26 c of liner 26 is disposed generally along a plane “P1”. Two sections of bottom edge 24 d and bottom edge 26 d are not aligned along planes “P” and “P1”. These two sections are located on projections 30 which extend outwardly for a distance below planes “P” and “P1”. The projections 30 comprise temporal regions on cap assembly 10 which are provided to extend over and cover the temples of the user wearing cap assembly 10. It should be noted that bottom edge 16 c of cap 11 is disposed either generally aligned with plane “P1” or a distance downwardly below plane “P1”. Consequently, when the cap assembly 10 is worn, as illustrated in FIG. 1, substantially little to none of the bottom edge 24 d of outer shell 24 or the bottom edge 26 d of liner is visible. The only portions of the insert that are visible are the two temporal regions or projections 30 and possibly a small section of the terminal regions 54 of the insert.

The upper edge 26 c of pad 26 is configured to have a pair of opposed depressions 56 (FIG. 4) formed therein to accommodate flanges 44. Upper edge 26 c further defines a recess 58 in the central region of shell 24 to accommodate part of the second strap 42 which is threaded through aperture 46 in frontal region 28 of shell 24. Pad 26 also includes a second engagement member in the form of the substantially horizontal detent 60 which extends outwardly from a bottom edge of frontal region 50 of liner 26. Detent 60 extends for a distance beyond frontal region 28 of shell 24 and toward the inner surface of outer wall 16 of cap 11. As best seen in FIG. 10, detent 60 extends for a short distance below peak 18 of cap 11. The weight of peak 18 on detent 60 aids in keeping insert 12 engaged on the user's head, particularly on the front of the user's head. Detent 60 also tends to prevent cap 11 from sliding downwardly on the user's head 14 and thus ensures that frontal regions 28, 50 are properly situated on the user's head to protect the forehead, temples and regions above the ears against impact.

Cap assembly 10 is substantially free of any protective components disposed on the exterior surface 16 a of wall 16. In other words, the exterior surface of cap assembly 10 has the appearance of a traditional baseball cap that is free of any protective elements. Only small parts of temporal regions 30, 52 are visible as these regions extend downwardly below bottom edge 16 c of cap 11 to protect the vulnerable temples of the user.

Cap assembly 10 is specifically designed for different head sizes using accurate human head CAD models in increments of two head sizes. This sizing is due at least partially to the fairly rigid and unforgiving outer shell 24 which is very specific to head size in order to keep the overall thickness of insert 12 thin enough so that cap 11 selected for the assembly 10 is only required to be a slightly larger hat size than normally would be worn by the user. The overall cap size for a user will tend to be around two or three larger hat sizes than would be the case if a regular baseball cap was to be worn. The user adjusts one or more of the bands/straps 34, 40 and 42 to ensure a snug fit for the insert 12 on the user's head 14.

The insert 12 provides significant protection from balls moving toward a user's forehead and/or sides of their head 14. This is due to the fact that most users, particularly ball players, are positioned to directly face the ball with either their foreheads or the sides of their head back to slightly rear of their ears. Furthermore, most users will instinctively turn their head to avoid a direct face hit and thereby bring their temples into a position where they could be struck by a flying ball. A ball hit in baseball is different than in football where the head is the projectile and cushioning in the football helmet has some distance to decelerate the brain. Cap assembly 10 is provided to protect against a ball hit where the impact from a ball hit must dissipate over a wider area where there is some compression of the underlying protective padding 26.

Referring now to FIGS. 12-20, there is illustrated a cap assembly 110 which includes a cap 11 and a second embodiment of a protective insert 112 (FIG. 13). Ball cap 11 is substantially identical to the cap shown in FIGS. 1-11 and therefore will not be described in any additional detail herein.

FIG. 13 illustrates insert 112 shown engaged on the user's head 14 while FIG. 14 illustrates insert 112 on its own and not engaged about a user's head 14. As with insert 12, insert 112 is not a traditional domed-hemispherical shape that would cover the entire head of the user. Instead, insert 112 is shaped, sized and located so as to protect only the user's forehead and an upper portion of the user's temples and areas immediately above the ears. The crown and back of the user's head do not have any portion of the insert 112 other than a flexible band 134 covering them, as will be later described herein. This configuration of insert 112 fits into a traditional ball cap 11 and protects the most vulnerable portions of the head but has the additional benefit of allowing air to circulate freely around the crown and back of the head. Additionally, this second embodiment of the insert 112 is substantially invisible because a bottom edge of the insert 112 is either aligned with a bottom edge 16 c of cap 11 or terminates a distance inwardly and upwardly from bottom edge 16 c. In other words, the bottom edge of insert 112 does not extend below bottom edge 16 c of cap 11. In other instances, however, the bottom edge of the insert 112 may project for a very short distance below bottom edge 16 c of cap 11.

Insert 112 is comprised of first and second components. The first component is an outer shell 124 that is received in a space defined by an interior surface of the ball cap 11. The second component is a liner or protective liner 126 that is received in a space defined by an inner surface of the outer shell 124, as will be described below. Liner 126 is configured to be complementary to outer shell 124. Liner 126 may be adhesively engaged to the inner surface of shell 124 or shell 124 may be placed in a mold and the foam liner 126 is then injection-molded around shell 124. Both shell 124 and liner 126 are generally U-shaped when viewed from above and include a central or frontal region which covers substantially all of the exterior surface of the user's forehead 14 a, particularly of the users upper forehead. Additionally, both shell 124 and liner 126 include side regions which are designed to cover upper portions of the side regions of the user′ head including portions of the temples and areas above the ears.

Referring to FIGS. 14-16, outer shell 124 has an exterior surface 124 a, an inner surface 124 b (FIG. 15), a top edge 124 c and a bottom edge 124 d. Liner 126 has an exterior surface 126 a (FIG. 15), an inner surface 126 b, a top edge 126 c, and a bottom edge 126 d. As is evident from the figures, liner 126 is configured to be engaged with outer shell 124 such that inner surface 124 b of shell 124 is adjacent exterior surface 126 a of liner 126. Outer shell 124 may be fabricated from a relatively thick, strong and rigid material such as a polycarbonate plastic. Liner 126 may be fabricated from a material that will tend to readily absorb impact forces. Liner 126 is provided to decelerate impact from a ball hit and may be fabricated from a visco-elastic material or a foam having a heavy density, such as a density of around 0.38 g/cm3.

Referring to FIGS. 15-21, outer shell 124 includes a central frontal region 128 sized and positioned to cover and protect most of the user's forehead 14 a. Outer shell 124 also includes a pair of opposed side or terminal regions 132 which extend rearwardly and outwardly from either side of the central frontal region 128. Terminal regions 132 may be positioned and shaped to cover and protect an upper portion of the sides of the user's head above the temple and above the ear 14 b (FIG. 11). Unlike outer shell 24, outer shell 124 does not include any temporal regions, similar to temporal regions 30, which will extend outwardly and downwardly below bottom edge 124 d of outer shell 124.

Outer shell 124 has a top edge 124 c and a bottom edge 124 d. A first portion of the top edge 124 c extends along a top end of the front regional 128, a second portion of the top edge 124 c extends along a top end of a first one of the temporal or side regions 30, and a third portion of the top edge 124 c extends along a top edge of a second one of the temporal or side regions 30. Frontal region 128 of outer shell 124 is of a height “H” (FIG. 17) measured between the first portion of the top edge 124 c and the bottom edge 124 d thereof. Terminal regions 132 are each of a height “Hi” measured between the associated second or third portion of the top edge 124 c and bottom edge 124 d. The height “Hi” is smaller than the height “H”. The entire bottom edge 124 d of outer shell 124, i.e., the bottom edge of frontal region 128 and the bottom edges of the first and second terminal regions 132 may be located in generally the same plane “P2”, as is illustrated in FIG. 17. This is not the case with the first portion of the top edge 124 c of the frontal region 128 and the second and third portions of the top edge 124 c of the terminal regions 132. The first portion of the top edge 124 c located on frontal region 128 is located a distance outwardly beyond the second and third portions of top edge 124 c located on terminal regions 132. An angled portion 131 (FIG. 17) of the top edge 124 c extends between the first portion of the top edge 124 c of frontal region 128 and teach of the second and third portions of the top edge 124 c of terminal regions 132.

A band 134 extends between the free ends of the two terminal regions 132 of shell 124. Band 134 is threaded through apertures 136 defined in each terminal region 132. Band 134 and outer shell 124 together form a closed loop that is adapted to circumscribe or encircle the circumference of the user's head.

Referring to FIG. 17 it can be seen that front region 128 of shell 124 is curved. (Liner 126 is similarly curved). This curvature results in the circumference of insert 112 being greatest proximate bottom edge 124 d of shell 124 and smallest proximate top edge 124 c. The difference in the circumference between top and bottom edges 124 c, 124 d is evident in FIGS. 18 and 19 where it can be seen that the distance between the interior surface of band 134 (which would be located adjacent the back of the user's head) and the interior surface of liner 126 (which would be located adjacent the user's forehead) decreases from the bottom (FIG. 18) to the top (FIG. 19) of insert 112. The circumference of insert 112 progressively decreases in size between the bottom edge and the top edge of insert 112. The curvature of insert 112 and the decreasing circumference thereof assists in keeping the insert 112 seated on the user's head 14 because the curvature and circumferential decrease mirrors the shape of the human head.

Band 134 may be fabricated from an elastic or resilient material and may be selectively adjustable in length so as to enable insert 112 to snugly fit the user's head. Band 134 may be semicircular in shape and is configured to form a horizontally oriented semicircular arch. Band 134 in conjunction with outer shell 124 fits circumferentially around the user's head 14 in a horizontal orientation. Band 134 may include any suitable type of closure mechanism thereon, such as hook and loop fasteners or, alternatively, band 134 may be threaded through apertures 136 and be simply stitched back upon itself.

It should be noted that there are no other bands or straps on insert 112. Particularly, there are no straps such as the straps 40 and 42 of cap assembly 12 which pass over the top of the user's head. The anatomical curvature of the user's upper forehead area 14 a is sufficient to keep the outer shell 124 of insert 112 on the forehead when the length of the band 134 is correctly adjusted.

Insert 12 is illustrated as including some suitable type of an engagement member provided on one or both of the outer shell 24 and interior surface of the cap 11 in order to secure insert 12 to cap 11. In that instance, the engagement member is disclosed as being one or more pin members 38, a detent 60 or hook and loop fasteners (not shown). Similar engagement members may be provided on insert 112 but no such engagement members are illustrated in FIGS. 12-20. While a detent 60 may be provided on insert 112, such a component is preferably omitted therefrom. Instead, the padding of liner 126 is trimmed so that bottom edge 126 d of liner 126 will be flush with bottom edge 124 d of shell 124 so as to limit the visibility of liner 126. Preferably, the only components keeping outer shell 124 engaged with cap 11 is a plurality of pin members (not shown in the figures) similar to pin members 38. It will be understood that any other type of engagement member may be utilized on outer shell 124 instead of the pin members. Inserts 12 and 112 are each of a type that is detachable and independent from cap 11 but it will be understood that either protective insert 12, 112 may be adhesively or otherwise permanently secured to cap 11.

Liner 126 is substantially complementary in shape to the rigid outer shell 124 of insert 112. Liner 126 is comprised of an impact absorbing padding material and only band 134 is free of any of padding material. As shown in FIG. 15, liner 126 includes a frontal or central region 150 and a pair of terminal or side regions 154. Terminal regions 154 extend outwardly from opposite sides of frontal region 150 and in opposite directions to each other. The upper edge 126 c of liner 126 includes angled sections 127 (FIG. 15) which are shaped and sized to be generally aligned with angled sections 131 on outer shell 124.

As indicated previously, liner 126 may be comprised of an impact-absorbing material and this material is substantially continuous along the entire inner surface 124 b of outer shell 124. Thus, there are substantially no regions on inner surface 124 b that are free of the impact-absorbing material. It will be understood that instead of liner 126 being continuous, there may be breaks or holes at intervals in the liner 126. Liner 126 may be a molded foam pad of complex geometry and may be thicker in frontal region 150 (FIG. 16) thereof than in the terminal regions 154 thereof. Liner 126 may taper in both height and thickness from frontal region 150 outwardly to terminal regions 154. This tapering will ensure that there is a smooth transition from shell 124 to band 134. The tapering pad thickness also helps ensure that the overall circumference of cap 11 is kept as small as possible. Shell 124 may be approximately 0.1″ thick and liner 126 may vary in thickness from about 0.1″ thick to about 0.32″ thick, with the thickness being measured between the respective interior and exterior surfaces of shell 124 and liner 126.

In insert 112, liner 126 may extend slightly beyond top edge 124 c of shell 124 so that a lip of foam padding extends above top edge 124 c. The foam lip may extend around substantially the entire top edge 124 c of shell 124 so there are no unprotected edges thereon that may injure or cut the user if impacted by a bat or ball. Liner 126 may be trimmed along its bottom edge 126 d so that bottom edges 124 d of shell 124 and bottom edge 126 d of liner are substantially horizontally aligned with each other. As best seen in FIG. 17, substantially the entire bottom edge 124 d of shell 124 and the entire bottom edge 126 d of insert 126 may be oriented along a plane “P2”. It should further be noted that bottom edge 16 c (FIG. 12) of cap 11 may be substantially aligned with bottom edges 124 d and 126 d f insert 112 along plane “P2”. This has the effect of making the protective insert 112 substantially invisible and gives the appearance that the user is wearing a regular ball cap and not a protective ball cap.

It will be understood that instead of the bottom edge 16 c of the cap being aligned with bottom edges 124 d, 126 d of insert 112, the bottom edges 124 d, 126 d may project for a short distance downwardly below bottom edge 16 c. Even in this instance, when the cap assembly 10 is worn, as illustrated in FIG. 12, substantially little to none of bottom edge 124 d of outer shell 124 or bottom edge 126 d of liner 126 may be visible.

Cap assembly 110, like cap assembly 10, is substantially free of any protective components disposed on the exterior surface 16 a of wall 16. In other words, the exterior surface of cap assembly 10 has the appearance of a traditional baseball cap that is free of any protective elements. Only small sections of outer shell 124 and protective liner 126 may be visible—if they extend partially below bottom edge 16 c of cap 11.

Cap assembly 110, like cap assembly 10, may be specifically designed for different head sizes using accurate human head CAD models in increments of two head sizes. This sizing is due, at least partially, to the fairly rigid and unforgiving material of the outer shell 124 which is fabricated to be very specific to a particular head size. This is done in order to keep the overall thickness of insert 112 thin enough so that cap 11 selected to be part of assembly 110 is only required to be a slightly larger hat size than normally would be worn by the user. The overall cap size for a user will tend to be around two or three larger hat sizes than would be the case if a regular baseball cap was to be worn. The user may adjust band 134 to ensure a snug fit for the insert 112 on the user's head 14.

Cap assembly 110 is used in substantially the same manner as cap assembly 10 and may provide protection against ball hits on the front and/or sides of the user′ head 14, as has been previously described.

In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed.

Moreover, the description and illustration of the preferred embodiment of the invention are an example and the invention is not limited to the exact details shown or described. 

1. A protective insert for a cap to be worn on a user's head, said insert comprising; an outer shell adapted to be received within a space defined by an inner surface of an outer wall of the cap; said shell being adapted to cover only the user's forehead and sides of their head; and an inner liner complementary in shape to the outer shell; wherein the liner is positioned adjacent an inner surface of the shell and is adapted to be disposed adjacent the user's head.
 2. The protective insert as defined in claim 1, wherein the outer shell is substantially rigid.
 3. The protective insert as defined in claim 1, wherein the inner liner is fabricated from a shock absorbent material.
 4. The protective insert as defined in claim 1, wherein the shell has a top edge and a bottom edge and the liner has a top edge and a bottom edge; and the bottom edges of the shell and the liner are substantially aligned along a same plane.
 5. The protective insert as defined in claim 4, wherein the bottom edge of the shell and the bottom edge of the liner are disposed in the same plane.
 6. The protective insert as defined in claim 1, wherein the outer shell has a first side edge and a second side edge, and the insert further comprises a band which extends between the first and second side edges.
 7. The protective insert as defined in claim 6, wherein the band and the outer shell together form a closed loop and the band and the outer shell together are adapted to encircle a wearer's head.
 8. The protective insert as defined in claim 7, wherein the closed loop formed by the outer shell and band have a circumference, and wherein the circumference of this closed loop decreases in size from proximate a bottom edge of the shell to proximate a top edge thereof.
 9. The protective insert as defined in claim 1, wherein the insert has a front region adapted to be positioned adjacent a user's forehead, and wherein the front region is curved from a bottom edge to a top edge thereof, and wherein the curvature of the front region is adapted to mirror a curvature of a user's forehead.
 10. The protective insert as defined in claim 6, wherein the band is selectively adjustable in length, and wherein adjustment of the length of the band changes a circumferential diameter of the insert.
 11. The insert as defined in claim 1, wherein each of the shell and the liner are generally U-shaped when viewed from above.
 12. The insert as defined in claim 1, wherein the shell includes a central region, a first side region and a second side region, wherein the first and second side regions extend outwardly in opposite directions from the central region; and wherein a first portion of the top edge of the shell extends along a top end of the central region, a second portion of the shell's top edge edges along a top end of the first side region; and a third portion of the shell's top edge extends along the second side region; and wherein the first portion of the top edge is disposed in a different plane to the second and third portions of the top edge.
 13. The protective insert as defined in claim 12, further comprising a first angled section extending between the first portion of the top edge and the second portion of the top edge; and a second angle section extending between the first portion of the top edge and the third portion of the top edge.
 14. The insert as defined in claim 12, wherein the central region is of a first height measured between the first portion of the shell's top edge and the bottom edge of the shell; and each of the first and second sides is of a second height as measured from the second portion of the shell's top edge or the third portion thereof to the bottom edge of the shell; and the first height is greater than the second height.
 15. The protective insert as defined in claim 1, wherein the liner comprises a layer of padding including a central region adapted to be disposed adjacent the user's forehead; and two opposed side regions each extending outwardly from opposing sides of the central region; wherein each of the side regions is adapted to be disposed adjacent one of the sides of the user's head, and wherein the padding has a thickness as measured from an exterior surface adjacent the shell and an interior surface adapted to be located adjacent the user's head; and wherein the central region of padding is thicker than the side regions of padding.
 16. A cap assembly for protecting a user's head; said assembly comprising: a cap including a substantially hemispherical outer wall having an inner surface and a bottom edge; a space defined by the inner surface of the outer wall; and a protective insert receivable within the space; wherein said insert comprises: an outer shell adapted to cover only the user's forehead and sides of their head; an inner liner complementary in shape to an interior surface of the outer shell; wherein the liner is adapted to be disposed adjacent the user's forehead and the sides of the user's head; wherein each of the shell and liner has a bottom edge and wherein the bottom edges of the liner and the shell do not extend beyond the bottom edge of the cap.
 17. The projective cap assembly as defined in claim 16, wherein the cap's outer wall is made from a fabric, the shell of the insert is fabricated from a rigid material and the liner of the insert is fabricated from an impact absorbing material.
 18. The protective cap assembly as defined in claim 16, further comprising a band connecting a first side of the shell to a second side of the shell, and wherein the band and shell together form a closed loop and are adapted to encircle the circumference of the user's head.
 19. The protective cap assembly as defined in claim 18, wherein the closed loop formed by the outer shell and band have a circumference, and wherein the circumference of this closed loop decreases in size from proximate a bottom edge of the shell to proximate a top edge thereof.
 20. The protective cap assembly as defined in claim 18, wherein the insert is free of any bands or components which will pass over a top region of the user's head.
 21. The protective cap assembly as defined in claim 16, wherein the protective insert is independent of and separate from the cap. 